Core wheel processing system and method

ABSTRACT

A method for processing core wheels is disclosed. Images of known wheels having unique identifying numbers and other wheel information is received from third party providers and are processed to determine the features of the known wheels. These images, features and other wheel information are stored in a database for future reference. A supply of core wheels is then provided and sorted in order to separate at least a first portion of the wheels conforming to a first set of criteria from the supply of wheels and are transported to second location.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Non-Provisional patentapplication Ser. No. 15/272,594, filed on Sep. 22, 2016, which claimedthe benefit of U.S. Non-Provisional patent application Ser. No.14/919,259, filed on Oct. 21, 2015, which in turn claimed the benefit ofU.S. Non-Provisional patent application Ser. No. 14/298,212 filed onJun. 6, 2014, which in turn claimed the benefit of U.S. ProvisionalPatent Application Ser. No. 61/831,824, filed on Jun. 6, 2013, each ofwhich is incorporated herein in its entirety by reference.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of Invention

The invention relates to reclamation of wheels. More specifically, thisinvention relates to a system and method for identifying wheel types andmodels of usable wheels.

2. Description of the Related Art

Used automobile wheels are often salvageable either for recycling oftheir constituent components or for additional use as a wheel. Forexample, if a used automobile wheel is not too badly worn or damaged, itmay be repaired or refurbished as necessary and reused as an automobilewheel. Alternatively, a used automobile wheel may be broken down intoits constituent components, whereupon the constituent components may bemelted and recycled or otherwise routed for subsequent use.

Aluminum automobile wheels are often made primarily of high purityaluminum alloy. However, certain designs of aluminum automobile wheelsmay also comprise paint, clearcoat, chrome plating, lead weights, brass,rubber, stainless steel, iron, or other materials. If a high purityaluminum alloy wheel is melted while contaminated with too much of theseother materials, the composition of the resultant melt will be a lesspure aluminum alloy having a decreased value as compared to a more purealuminum alloy. Therefore, prior to reclaiming and/or recycling ofautomobile wheels, it is often desirable to separate those automobilewheels which comprise high purity aluminum alloy and which do notinclude high levels of additional contaminants from those automobilewheels which either a.) are not fabricated primarily from high purityaluminum alloy; or b.) further comprise an unacceptably high amount ofadditional contaminants. In several reclaiming and/or recyclingapplications, it is desirable to sort automobile wheels by model andtype, such that multiple wheels of the same model and type are groupedtogether, for example to form a complete set of wheels for a given typeof automobile.

In light of the above, a system and method for recovering high purityaluminum alloy wheels from the remainder of a supply of used automobilewheels, and for further identifying wheel types and models of reusablewheels from the recovered high purity aluminum alloy wheels, is desired.

BRIEF SUMMARY OF THE INVENTIVE CONCEPT

The present general inventive concept provides a system for processingcore wheels comprising a sorting station to allow sorting of a source ofwheels according to a first set of criteria, a conveyor to receivewheels conforming to the first set of criteria and to direct thereceived wheels toward the discharge end of the conveyor, a firstinspection station along the conveyor to allow examination of the wheelsto determine whether the wheels conform to a second set of criteria, adiverter mechanism along the conveyor to divert wheels conforming to thesecond set of criteria from the first conveyor onto a second conveyor;and a second conveyor to receive the diverted wheels and direct thediverted wheels to a second inspection station for inspection to confirmthat the diverted wheels conform to the second set of criteria.

The first inspection station of the system may include a camera tocapture images of wheels carried along the conveyor.

The first inspection station of the system may include a light hood forcontrolling the amount of light on the wheels and thereby enhancing thequality of the images captured by the camera.

The first inspection station of the system may include a monitor incommunication with the camera to display images captured by the camera.

The first inspection station of the system may include a controlmechanism in operational communication with the diverter mechanismallowing a user to divert wheels conforming to the set of criteria fromthe first conveyor to the second conveyor in response to imagesdisplayed by the monitor.

The first inspection station of the system may include a control modulein operational communication with the camera and the diverter mechanism,with said control module having a computer, integrated into or otherwisein communication with the control module, and computer software capableof processing the image of the wheel received from the camera, findingpotential matches of said image with images of known wheels stored in awheel feature database, comparing the potential wheel matches to a buylist and other business criteria, making a decision whether or not tokeep the wheel, and triggering the diverter mechanism for wheelsselected to be kept.

The first inspection station of the system may include a wheel sensor inoperational communication with the control module to notify the controlmodule that a wheel is approaching the camera, with the control modulealso in operational control of the camera, the diverter mechanism andthe motors of the conveyors, thus automating the operation of the firstinspection station and the operation of the diverter mechanism bytransporting the wheels at equal intervals on the conveyors andsignaling the diverter mechanism to activate when a selected wheel movesin front of the diverter mechanism.

The system may include additional conveyors with, for example, a firstconveyor controlled by the control module and configured to receiveincoming wheels, a second conveyor controlled by the control module andconfigured to receive equally spaced wheels from the first conveyor, agravity powered third conveyor configured to receive wheels pushed offthe second conveyor by the diverter mechanism, a fourth conveyorcontrolled by the control module and configured to receive wheels notdiverted by the diverter mechanism, and a continuously running fifthconveyor configured to receive wheels from the discharge end of thefourth conveyor.

The control module of the system may include a computer and computersoftware designed to receive, process and store wheel images andfeatures of known wheels with unique identifying numbers to populate awheel feature database for known wheels. The computer software may alsobe designed to build and store a K-nearest neighbor classifier forsubsequent matching.

The computer integrated into or in communication with the control moduleof the system may also include computer software designed to receive andprocess unknown wheel images received from the camera and to compare theimages and features of the unknown wheel to images and features of theknown wheels stored in the wheel feature database and to generatepotential known wheel matches for the unknown wheel.

The computer integrated into or in communication with the control moduleof the system may also include computer software designed to compare thepotential matches for an incoming wheel to a buy list and other businesscriteria and make a decision whether or not to keep the incoming wheel.

The image processing portion of the computer software for the computerintegrated into or in communication with the control module may alsoinclude subroutines designed to analyze the image of a wheel, todetermine the wheel boundary and the center of the wheel, to computeFourier transform magnitudes of sampled points on multiple circlesaround the center of said wheel, and to generate features of said wheelfrom the image of said wheel. The computer software may also compare thefeatures of an unknown wheel with the features of known wheels byapplying the K-nearest neighbor classifier to the features of theunknown wheel to determine the nearest potential matches of the unknownwheel with known wheels in the wheel feature database. The computersoftware may also determine the relative closeness of each matchpotential match by calculating the distance of the features of the wheelthat is a potential match from the features of the unknown wheel.

The system may include a first storage container positioned proximatethe second inspection station to receive wheels conforming to both thefirst and second sets of criteria.

The system may include a second storage container positioned proximatethe discharge end of the first conveyor to receive wheels conforming tothe first set of criteria but failing the second set of criteria.

The system may include additional conveyors and components with, forexample, a zoned accumulation first conveyor controlled by the controlmodule and configured to receive incoming wheels, a second conveyorcontrolled by the control module and configured to receive a wheel fromthe first conveyor and transport the wheel under the camera, a thirdconveyor controlled by the control module and configured to receive thewheel from the second conveyor, a gravity powered fourth conveyorconfigured to receive wheels pushed off the third conveyor by thediverter mechanism, a fifth conveyor controlled by the control moduleand configured to receive equally spaced wheels not diverted by thediverter mechanism and transport them through a cleaning station, azoned accumulation sixth conveyor configured to receive wheels from thefifth conveyor and accumulate wheels while they are loaded onto pallets,a gravity powered seventh conveyor deck attached to a hydraulic scissorlift and configured to hold a pallet while wheels are loaded onto apallet and wrapped for shipping, and a zoned accumulating eighthconveyor configured to receive wrapped pallets of wheels from theseventh conveyor deck and accumulate pallets awaiting removal by a forklift.

The system may include an infrared sensor configured to measure theheight and width of a wheel and to communicate the measurements to thecontrol module for storage in the wheel feature database.

The present general inventive concept provides a method for processingcore wheels comprising providing a supply of wheels to a first location,sorting the wheels to separate at least a first portion of the wheelsconforming to a first set of criteria from the supply of wheels,transporting the first portion of the wheel supply to a second location,separating a second portion of the wheels conforming to a second set ofcriteria from the first portion of the wheels, transporting the secondportion of the wheels to a third location, verifying conformity of thesecond portion of the wheels to the second set of criteria, andtransporting the remainder of the first portion of the wheels to afourth location.

The method may include first criteria that selects only wheels that arenot chrome plated and not used for semi-trailer trucks.

The method may include first criteria that selects only wheels that arefabricated from aluminum alloy.

The method may include second criteria that selects only wheels that arenot too badly worn or damaged and that are capable of being used withspecific makes and/or models of automobiles.

The method may include the operation of separating a second portion ofthe wheels conforming to a second set of criteria and performing avisual inspection of the first portion of the wheels duringtransportation to the second location.

The method may include the visual inspection being performed using acamera to capture images of the first portion of the wheels during thetransportation operation.

The method may further include controlling ambient light and enhancingthe light on the wheels in order to enhance the quality of the imagescaptured by the camera.

The method may include the operation of separating a second portion ofthe wheels conforming to a second set of criteria further by, forexample, actuating a sensor arm to divert wheels conforming to thesecond set of criteria for transportation to the third location.

The method may include the operation of receiving images of known wheelshaving unique identifying numbers from third parties, processing theimages of the wheels to determine the features of the wheels, andstoring the features of the wheels in a wheel feature database togetherwith the unique identifying numbers. The method may include theoperation of analyzing the digital image of an unknown wheel,determining the wheel boundary and the center of the wheel, samplingsampled points on multiple circles around the center of the wheel, andcomputing Fourier transform magnitudes of sampled points on multiplecircles to generate features of the wheel. The method may also includethe operation of building and storing a K-nearest neighbor classifierfor subsequent matching.

The method may include the operation of comparing the features of anunknown wheel to features of known wheels stored in the wheel featuredatabase. The method may include the operation of analyzing the digitalimage of the unknown wheel, determining the wheel boundary and thecenter of the wheel, sampling sampled points on multiple circles aroundthe center of the wheel, and computing Fourier transform magnitudes ofsampled points on multiple circles to generate features of the wheel.The method may also include the operation of applying the K-nearestneighbor classifier to the features of the unknown wheel to determinethe nearest matches of the unknown wheel with known wheels in the wheelfeature database. The method may also include the operation ofdetermining the relative closeness of each match potential match bycalculating the distance of the features of the wheel that is apotential match from the features of the unknown wheel.

The method may include the operation of comparing wheels thatpotentially match known wheels with wheels on a buy list and otherdesirable wheels based on other business criteria.

The method may include the operation of cleaning the wheels that do notmeet all of the matching criteria.

The method may include the automation of the operation of the firstinspection station and the operation of the diverter mechanismcomprising a control module in operational control of the wheel sensor,the camera, the diverter mechanism and the motors of the conveyors totransport the wheels at equal intervals on the conveyor to the divertermechanism and activating the diverter mechanism when a selected wheelmoves in front of the diverter mechanism.

The method may include the operation of positioning a source of wheelsmeeting the first set of criteria for loading onto the receiving end ofthe first conveyor.

The method may include the operation of taking measurements of the wheeland storing the measurements of the wheel in the wheel feature databaseto limit the number of known wheels to be compared to an unknown wheelin the wheel matching process.

The method may include the operation of raising a pallet to the level ofthe conveyor for the incoming wheels, sequentially lowering the palletto the level of the incoming conveyor as the loading of each layer ofwheels is completed, and raising the level of the pallet to the level ofthe outgoing conveyor once the pallet is fully loaded.

The method may include the operation of securing layers of wheels to apallet by wrapping multiple layers of wheels in overlapping wrappingmaterial as the wheels are loaded onto the pallet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The above-mentioned features of the invention will become more clearlyunderstood from the following detailed description of the invention readtogether with the drawings in which:

FIG. 1 is a schematic representation of an example embodiment of a corewheel processing system according to several features of the presentgeneral inventive concept;

FIG. 2 is a schematic representation of another example embodiment of acore wheel processing system according to several features of thepresent general inventive concept;

FIG. 3 is a diagram illustrating one example embodiment of the firstinspection station showing the control module in operative communicationwith the wheel sensor and in operative control of the camera, thediverter mechanism, the switch of the first conveyor motor, the switchof the second conveyor motor, and the switch of the fourth conveyormotor in the example embodiment of the core wheel processing systemillustrated in FIG. 2;

FIG. 4 is a schematic representation of another example embodiment of acore wheel processing system according to several features of thepresent general inventive concept;

FIG. 5 is a diagram illustrating one example embodiment of the firstinspection station showing the control module in operative communicationwith two wheel sensors and an infrared sensor and in operative controlof the camera, the diverter mechanism, the controller of the firstconveyor motor, the controller of the second conveyor motor, thecontroller of the fourth conveyor motor, and the controller of the fifthconveyor motor in the example embodiment of the core wheel processingsystem illustrated in FIG. 7;

FIG. 6 is a diagram illustrating one example embodiment of the steps thecontrol module and its computer perform in loading the wheel featuredatabase with images of known wheels and the steps the control moduleand its computer perform in matching unknown wheel images to known wheelimages stored in the wheel feature database;

FIG. 7 is a flow diagram illustrating one example embodiment of thesteps the computer software of the computer integrated into or incommunication with the control module performs in loading the wheelfeature database with images of known wheels;

FIG. 8 is a flow diagram illustrating one example embodiment of thesteps the computer software of the computer integrated into or incommunication with the control module performs in matching images ofunknown wheels to images of known wheels stored in the wheel featuredatabase;

FIG. 9 is a flow diagram illustrating one example embodiment of thesteps performed by the second inspection station in confirming matchesof unknown wheels to known wheels and taking follow-up actions;

FIGS. 10A and 10B are perspective views, respectively, of a cameracompartment for controlling the lighting of the camera system in orderto improve picture quality;

FIGS. 11A and 11B are elevation and cross-sectional views, respectively,of the camera compartment illustrated in FIGS. 10A and 10B; and

FIGS. 12A and 12B are elevation and cross-sectional views, respectively,of the camera compartment illustrated in FIGS. 10A and 10B.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a schematic representation of an example embodimentof a core wheel processing system and method according to severalfeatures of the present general inventive concept. The core wheelprocessing system and method, or system, is identified as 10 herein andin the accompanying figures.

With initial reference to FIG. 1, in one embodiment of a system 10according to several features of the present general inventive concept,a supply of wheels, such as for example used or scrap wheels, isdelivered 14 to a wheel bin 12. Thereafter, an initial sorting operation16 is performed. In several embodiments, the initial sorting operation16 is configured to separate at least a first portion of the wheelsupply, conforming to a first set of criteria for acceptable orunacceptable wheels, from at least a second portion of the wheel supplywhich fails the first set of criteria. For example, in the illustratedembodiment, the first set of criteria may be the unacceptability ofchrome-plated wheels and/or wheels used for semi-trailer trucks. In thisembodiment, the initial sorting operation 16 includes separation ofchrome-plated wheels and wheels used for semi-trailer trucks 18 from aremainder of the supply of wheels. The separated chrome-plated wheelsand wheels used for semi-trailer trucks 18 may, in certain embodimentsbe discarded following the initial sorting operation 16. In otherembodiments, the chrome-plated wheels and wheels used for semi-trailertrucks 18 may, following the initial sorting operation 16, be directedfor further processing, such as for example for processing in arecycling or other reclamation process. In some embodiments, the initialsorting operation 16 may be performed by a first operator 20 by visuallyinspecting and manually separating the first portion of the wheel supplyfrom a remainder of the wheel supply. However, those skilled in the artwill recognize other suitable devices and operations by which theinitial sorting operation 16 may be performed, and such other devicesand operations may be used without departing from the spirit and scopeof the present general inventive concept.

Following the initial sorting operation 16, the remainder of the supplyof wheels which were not separated into the first portion during theinitial sorting operation 16 (hereinafter, the “wheels”) may be placedonto a first conveyor 22. The first conveyor 22 is configured totransport the wheels to a second sorting operation 26, whereby at leasta portion of the wheels, which conform to a second set of criteria foracceptable or unacceptable wheels, are separated from the remainder ofthe wheels which fail the second set of criteria. For example, inseveral embodiments, a second set of criteria is established whereinwheels which are not too badly worn or damaged and which are capable ofbeing used with particular makes and/or models of automobiles are deemedacceptable. It will be understood that the specific terms of the secondset of criteria, such as for example the particular makes and/or modelsof automobiles matching the second set of criteria or the degree towhich a wheel may be damaged and/or worn without failing the second setof criteria, may depend upon the specific needs and/or capabilities ofthe users of the system 10, and as such may vary without departing fromthe spirit and scope of the present general inventive concept. Forexample, as will be discussed in further detail below, in severalembodiments, the second sorting operation 26 includes a high-speedcomparison of an image of each wheel to images of wheels from adatabase. In certain of these embodiments, wheels conforming to one ormore image of an acceptable wheel from the database may be separatedfrom the remainder of the wheels. In certain embodiments, the databaseand/or the second set of criteria for acceptable wheels is updatable.

In the illustrated embodiment, the second sorting operation 26 includestransportation of the wheels via the first conveyor 22 to a firstinspection station 204 for inspection. In the illustrated embodiment,the first inspection station 204 comprises a camera 24 which is directedtoward a carrying surface of the first conveyor 22, such that the camera24 may capture images of the wheels as they pass by the camera 24 on thefirst conveyor 22. For each wheel for which an image is captured by thecamera 24, an image of the wheel is examined to determine whether thewheel conforms to, or fails, the second set of criteria. For example, inseveral embodiments, each image of the wheel is subjected to ahigh-speed comparison to a database of wheel images using imageprocessing techniques to determine whether the wheel captured by thecamera 24 conforms to the characteristics of a known wheel type in thedatabase. In one such embodiment, the camera 24 is in communication witha microprocessor such that the microprocessor may receive capturedimages from the camera 24. The microprocessor is, in turn, incommunication with a data storage device. A database of images of wheelsis stored on the data storage device, with each stored wheel imagehaving one or more feature vectors associated therewith. The featurevectors associated with the stored wheel images correlate to features ofthe wheel shown in the stored wheel image. Upon capturing an image of awheel passing by the camera 24, the captured image may be received bythe microprocessor from the camera 24. Thereafter, the microprocessormay extract and/or compute one or more feature vectors from the capturedimage which correlate to features of the wheel shown in the capturedimage. The microprocessor may then compare the feature vectors from thecaptured image with feature vectors of the stored wheel images in thedatabase, such that the microprocessor may identify one or more relevantstored wheel images from the database showing wheels with featuressimilar to features of the wheel in the captured image.

In several embodiments, each wheel image stored in the database furtherincludes data corresponding to an identification of the type of wheelshown in the stored image, such as for example the year, make, modeland/or type of wheel, or a part number or reference number correspondingto the particular wheel. Each wheel image stored in the database mayfurther include data indicating whether the particular type of wheelshown in the stored image conforms to the second set of criteria usedfor the second sorting operation 26. Thus, by determining whether thewheel shown in the image captured by the camera 24 conforms to thefeatures of any of the stored wheel images in the database, and bydetermining for each stored wheel image conforming to the captured imagewhether the stored wheel image conforms to the second set of criteria,the microprocessor may determine whether the wheel shown in the capturedimages conforms to, or fails, the second set of criteria. In severalembodiments, the data indicating whether the particular type of wheelshown in the stored image conforms to the second set of criteria isupdatable. For example, in some embodiments, the data storage deviceincludes an input for receiving updated data as to which types of wheelsand/or which of the stored images conforms to the second set ofcriteria. In certain more discreet embodiments, such updated data isprovided on a set schedule, such as for example weekly. Thus, the system10 may be used, for example, to identify wheels conforming to a list ofwheel types needed to fill a particular order. However, those of skillin the art will recognize other configurations for the data storagedevice which may be used without departing from the spirit and scope ofthe present general inventive concept.

In some embodiments, the microprocessor is configured to perform acomparison of the features of the captured image versus the features ofthe stored images to determine whether the wheel in the captured imageis identical, or substantially identical, to any of the wheels shown inthe stored images. However, in other embodiments, the microprocessor isconfigured to determine whether the wheel in the captured image issufficiently similar to any of the wheels shown in the stored images towarrant further examination. For example, in one embodiment, themicroprocessor is configured to compare only features of the outerportions of the wheel, and to disregard portions of the wheel near thecentral axis of the wheel. Thus, in this embodiment, the system 10 isconfigured such that the second sorting operation 26 may take intoaccount the possibility that the wheel may or may not include a centercap, hub cap, or the like, and does not perform a determination ofconformity to the second set of criteria based on a visual inspection ofthe central portions of the wheel. In another embodiment, themicroprocessor is configured to determine whether the wheel shown in theimage captured by the camera 24 conforms to any of the stored wheelimages in the database based on similarities in only a portion of thecorresponding feature vectors of the captured image and the stored wheelimages. Thus, in this embodiment, the system 10 is configured such thatwheels containing minor defects and/or imperfections may still beidentified as conforming to the second set of criteria.

In another embodiment, inspection of each captured image is performedmanually by a second operator 28. More specifically, in someembodiments, the camera 24 is provided in communication with a monitor30, such that images captured by the camera 24 are displayed on themonitor 30 for viewing by the second operator 28. Thus, the secondoperator 28 is able to view the images of the wheels displayed on themonitor 30 and determine whether each of the wheels depicted in theimages conforms to, or fails, the second set of criteria. Those of skillin the art will recognize other means by which the second sortingoperation 26 may be performed, and such other means may be used withoutdeparting from the spirit and scope of the present general inventiveconcept.

In several embodiments, the system 10 includes suitable apparatuspositioned downstream of the first inspection station 204 such that,once a determination is made as to whether each of the wheels conformsto, or fails, the second set of criteria, those wheels which conform tothe second set of criteria may be separated from those wheels which failthe second set of criteria. For example, in the illustrated embodiment,a sensor arm 32 is provided along the first conveyor 22 and is capableof directing selected wheels from the first conveyor 22 to a secondconveyor 34. In several embodiments, the sensor arm 32 is selectivelymovable between a first position and a second position. In the firstposition, the sensor arm 32 permits wheels on the first conveyor 22 tocontinue travelling along the first conveyor 22 beyond the sensor arm32. In the second position, the sensor arm 32 diverts wheels from thefirst conveyor 22 and directs the diverted wheels onto the secondconveyor 34. In the illustrated embodiment, the sensor arm 32 is inoperative communication with a suitable control mechanism, such as forexample a switch, lever, or other suitable device, in communication withthe microprocessor, which allows the sensor arm 32 to be moved betweenthe first and second position in response to determinations ofconformity to the second set of criteria by the microprocessor. Thus,upon determining whether each wheel passing the camera conforms to orfails the second criteria, the sensor arm 32 may be moved between thefirst and second position to direct each wheel to one of the first andsecond conveyors 22, 34 based on such determination.

In other embodiments, the camera 24 is provided in operativecommunication with a computer (not shown) having appropriate imagerecognition software, of the type known to one of skill in the art, suchthat the computer is able to analyze an image provided by the camera 24and determine whether a wheel depicted in the image conforms to, orfails, the second set of criteria. Upon a determination that the wheeldepicted in the image conforms to the second criteria, a signal isgenerated. In certain embodiments, the sensor arm 32 is configured to beresponsive to the signal such that, upon receipt of the signal, thesensor arm 32 is moved between the first and second position. Thus, inthese embodiments, the camera 24, computer, and sensor arm 32 cooperateto automatically direct each wheel to one of the first and secondconveyors 22, 34 based on the determination of the computer.

As discussed above, in several embodiments, the second criteria isestablished such that wheels which are not too badly worn or damaged andwhich sufficiently conform to particular makes and/or types of wheels asdetermined by the database comparison are deemed acceptable. In certainof these embodiments, operation of the sensor arm 32 is performed suchthat acceptable wheels, according to the second criteria, are directedonto the second conveyor 34, while unacceptable wheels, according to thesecond criteria, are allowed to continue on the first conveyor 22. Thefirst conveyor 22 carries the unacceptable wheels to a discharge end 36of the first conveyor 22, whereupon the unacceptable wheels may beloaded onto one or more weigh scales 40, or other suitable holdingapparatus, for further processing, such as for example for processing ina recycling or other reclamation process. In the illustrated embodiment,the unacceptable wheels are removed from the discharge end 36 of thefirst conveyor 22 and loaded onto the weigh scale 40 manually by aplurality of third operators 42. In certain embodiments, additionalsorting of the unacceptable wheels based on additional criteria forrecyclability may occur. In another embodiment, the discharge end 36 ofthe first conveyor 22 empties into the weigh scale 40, such that noadditional individual handling of the unacceptable wheels is necessary.

As discussed above, operation of the sensor arm 32 is performed suchthat acceptable wheels, which in the present embodiment are wheels whichsufficiently conform to particular makes and/or types of wheels asdetermined by the database comparison, are directed onto the secondconveyor 34. The second conveyor 34 transports the acceptable wheels toa final inspection and loading station 44, whereupon the acceptablewheels may be subjected to a final inspection and loaded onto one of aplurality of suitable holding devices for transportation to a secondarylocation for refurbishment, as needed, before being directed towardreuse. In one embodiment, the final inspection operation includesplacing the wheel on a suitable apparatus whereby a visual inspection ofthe wheel may be made. For example, in one embodiment, the finalinspection operation includes placing the wheel on a rotatable mount androtating the wheel. As the wheel is rotated on the rotatable mount, thewheel may be visually inspected by the second operator 28 to confirmthat the wheel is acceptable for refurbishment and/or reuse. Uponpassing the final inspection, the wheel may be loaded onto at least onecore skid 46 for transportation to the secondary location. If the wheelfails to pass the final inspection, it may be placed in a scrapcontainer 48 and discarded. In the illustrated embodiment, the system 10is configured such that the final inspection and loading station 44 isoperated by the second operator 28. However, those of skill in the artwill recognize other configurations suitable for operation of the finalinspection and loading station 44, and such other configurations may beused without departing from the spirit and scope of the present generalinventive concept.

In several embodiments, the system 10 is configured to allow additionalsorting of wheels which pass the final inspection, for example, intogroups of wheels the sum of which meet an additional criteria, such asto fill a particular order or request for a particular number and/ortype of wheels. For example, in one embodiment, a plurality of coreskids 46 are provided, with each core skid 46 corresponding to an orderfor a complete set of usable and/or refurbishable wheels for aparticular automobile. In this embodiment, the second set of criteriamay be established wherein acceptable wheels are those wheels which arecapable of being reused or refurbished and which also correspond to oneof the desired types of wheels needed to complete at least one of theorders corresponding to the core skids 46. Upon completion of an ordervia loading the acceptable number and type of wheels onto theappropriate core skid 46, the completed core skid 46 may be transportedto a secondary location, such as for example to a location whererefurbishing of the wheels may occur or directly to a customer.

FIG. 2 is a schematic illustration of another embodiment of a system 201constructed in accordance with several features of the present generalinventive concept. In the embodiment of FIG. 2, the system 201 includesa sorting station 202 which is configured to allow initial sorting of asource of wheels according to a first set of criteria, with wheels notmatching the first set of criteria being placed in a first scrapreceptacle 48 a. A loading station 206 is provided, which is configuredto allow placement of each wheel matching the first set of criteria ontoa first conveyor 203. The first conveyor 203 is configured to receiveincoming wheels, to convey the incoming wheels to a location forexamination of the wheels for sorting according to a second set ofcriteria, and to discharge the wheels evenly spaced onto a secondconveyor 208.

Referring to the example embodiment illustrated in FIG. 2, the firstconveyor 203 defines a plurality of regions, or “zones,” along thelength thereof for positioning and accumulation of incoming wheels forsorting according to the second set of criteria. In one embodiment, afirst inspection station 204 is disposed along the first conveyor 203proximate two of the plurality of zones, identified as “zone 1” and“zone 2” in FIG. 2. The first inspection station 204 is equipped with awheel sensor 205 disposed along the first conveyor 203 to detect a wheelmoving from the loading station 206 into zone 2 of the first conveyor203. The first inspection station 204 is further equipped with a camera24 in operative communication with the wheel sensor 205 and configuredto view objects positioned at zone 1 on the first conveyor 203.

In the example embodiment illustrated in FIG. 2, upon detection of awheel at a location along the first conveyor 203 proximate zone 2, thewheel sensor 205 is configured to signal a control module 207, whereuponthe control module 207 is configured to stop the first conveyor 203 withthe wheel in zone 2. The control module 207 may then signal the firstconveyor 203 to move the incoming wheel into zone 1 of the firstconveyor 203. The camera 24 disposed above zone 1 of the first conveyor203 may then be signaled to capture an image of the wheel and tocommunicate the image to the control module 207. The control module 207may then signal the first conveyor 203 to start and move the wheel tothe discharge end of the first conveyor 203. As will be furtherdiscussed herein below, the camera 24 is in communication with acomputer processing device which is configured to identify the wheelimaged by the camera 24 and to compare the identified wheel to a secondset of criteria to determine if the wheel is to be kept.

A second conveyor 208 is provided which is configured to receive aplurality of evenly spaced wheels discharged by the first conveyor 203.The second conveyor 208 is configured to direct the received wheels to adiverter mechanism 209, whereupon the diverter mechanism 209 may divertwheels conforming to the second set of criteria from the second conveyor208 onto the third conveyor 213. In several embodiments, the divertermechanism 209 comprises a piston, lever arm, or other such device.However, those of skill in the art will recognize other suitable deviceswhich may be used to accomplish the operation performed by the divertermechanism 209 without departing from the spirit and scope of the presentgeneral inventive concept. In several embodiments, the second conveyor208 maintains the spacing of the received wheels along a length of thesecond conveyor 208 in order to assist in timing of the divertermechanism 209.

In the example embodiment illustrated in FIG. 2, the third conveyor 213is configured to receive the diverted wheels and to direct the divertedwheels to a second inspection station 211. The second inspection station211 is disposed along the third conveyor 213 and is configured to allowexamination of the diverted wheels by an operator 28. At the secondinspection station 211, the operator 28 may confirm whether each wheelconforms to the second set of criteria. Wheels conforming to the secondset of criteria may be placed onto a core skid 46, and wheels notconforming to the second set of criteria may be placed in a second scrapreceptacle 48 b and discarded.

Those wheels not diverted by the diverter mechanism 209 are carried bythe second conveyor 208 to a discharge end of the second conveyor 208. Afourth conveyor 214 is provided to receive the wheels from the dischargeend of the second conveyor 208 and to direct the received wheels througha cleaning station 215 and on to the discharge end of the fourthconveyor 214. The cleaning station 215 is configured to manipulate andclean the wheels prior to the wheels being discharged onto a fifthconveyor 216. A fifth conveyor 216 is configured to receive the cleanwheels discharged from the fourth conveyor 214 and to direct them into abin area 217.

In the example embodiment illustrated in FIG. 2, the first conveyor 203,second conveyor 208, and fourth conveyor 214 are each electronicallycontrolled by the control module 207, which is also in operativecommunication with the wheel sensor 205. Thus, the control module 207may signal each conveyor to advance as needed to maintain sufficientpace and spacing of wheels along the first, second, and fourth conveyors203, 208, 214. In the illustrated embodiment, the fifth conveyor 216 isconfigured to run continuously, while the third conveyor 213 is agravity-driven conveyor, such as for example a ramp or other suitabledevice. However, those of skill in the art will recognize other meansfor controlling the various conveyors 203, 208, 213, 214 which may beused without departing from the spirit and scope of the present generalinventive concept. For example, in other embodiments, the third conveyor213 may be powered by automated means known to those of skill in theart.

In the example embodiment illustrated in FIG. 2, the control module 207is in communication with a computer (not shown), with said computerhaving appropriate image recognition software, of the type known to oneskilled in the art, such that the computer is able to analyze an imageprovided by the camera 24, identify the closest matches to the imagedwheel from a wheel feature database stored in the computer, anddetermine whether the wheel depicted in the image conforms to, or fails,the second set of criteria. Upon a determination that the wheel depictedin the image conforms to the second set of criteria, a signal isgenerated by the control module 207 and communicated to the divertermechanism 209 in cooperation with the movement of the wheel along thesecond conveyor 208 and the arrival of the wheel in front of thediverter mechanism 209. In the embodiments illustrated in FIG. 2, thediverter mechanism 209 is configured to be responsive to the signal suchthat, upon receipt of the signal, the diverter mechanism 209 isactivated to push the wheel from the second conveyor 208 onto the thirdconveyor 213. Thus, in this embodiment, the camera 24, the computer inthe control module 207, the second conveyor 208, and the divertermechanism 209 work in cooperation with one another to automaticallydirect each wheel either to the third conveyor 213 for confirmation bythe operator 28 or to the discharge end of the second conveyor 208 basedon the determination of the computer integrated into or otherwise incommunication with the control module 207.

In some embodiments, the first inspection station 204 is automated tocontrol the movement of the first conveyor 203, the second conveyor 208,and the fourth conveyor 214, so that the wheels are evenly spaced asthey pass in front of the diverter mechanism 209. Referring now to FIG.2 and FIG. 3, the wheel sensor 205 initiates a signal to the controlmodule 207 when a wheel is approaching the camera 24, and in response tothe signal, the control module 207 stops the first conveyor 203 with thewheel in zone 2 of the first conveyor 203. After the control module 207determines that the diverter mechanism 209 is no longer in a push cycle,the control module 207 signals a switch 301 to start a motor 302 topropel the first conveyor 203 to a point where the wheel is position inzone 1 of the first conveyor 203 under the camera 24, signals the camera24 to capture the image of the wheel, and then signals the switch 301 tostart the motor 302 to advance the first conveyor 203 to run until thenext incoming wheel is detected by the wheel sensor 205. When the firstconveyor 203 has moved the distance required to discharge the wheel ontothe second conveyor 208, the control module 207 signals a switch 305 tostart a motor 306 and advance the second conveyor 208 a set distance. Ifthe second conveyor 208 discharged a wheel onto the fourth conveyor 214,the control module 207 also signals a switch 309 to start a motor 310and advance the third conveyor 214 the same set distance. In someembodiments, the second conveyor 208 and the fourth conveyor 214 areeach advanced a selected distance, thirty-four (34) inches in anexemplary embodiment, each time they are advanced so that the wheelsremain evenly spaced on the second conveyor 208 as they move in front ofthe diverter mechanism 209 and remain evenly spaced on the fourthconveyor 214 as they move into the cleaning station 215. This equalspacing of the wheels allows the control module 207 to track thelocation of each wheel and signal the diverter mechanism 209 to pusheach wheel matching the set of criteria from the second conveyor 208onto the third conveyor 213 as the matching wheel moves in front of thediverter mechanism 209. This equal spacing of the wheels also places thewheels on the fourth conveyor 214 in the proper position for pickup andmanipulation as each wheel enters the cleaning station 215. In otherembodiments, a wheel sensor may be disposed at the receiving end of thefourth conveyor 214 to detect whether a wheel is present and to notifythe control module not to advance the fourth conveyor 214 the setdistance if no wheel is present, thus permitting the fourth conveyor 214to maintain even spacing of wheels with no gaps where wheels have beendiverted onto the third conveyor 213. One of skill in the art willunderstand that the above-mentioned example dimensions are not meant tobe limiting, and that other values may be substituted for the setdistance of thirty-four inches for advancement of the respectiveconveyors without departing from the scope or spirit of the presentgeneral inventive concept. Further, one of skill in the art willunderstand that suitable controllers may be substituted for theabove-mentioned switches 302, 306, 310 without departing from the scopeor spirit of the present general inventive concept.

FIG. 4 is a schematic illustration of another embodiment of a system 401constructed in accordance with several features of the present generalinventive concept. In this example embodiment, the system 401 includes asorting station 202, a loading station 206, a first conveyor 203, asecond conveyor 405, a third conveyor 208, a diverter mechanism 209, afourth conveyor 213, a fifth conveyor 214, a cleaning station 215, asixth conveyor 216, a wrapper station 407 with a seventh conveyor deck,an eighth conveyor, an inspection station 204 a, which further includesa control module 207, a wheel sensor 205 a, a wheel sensor 205 b, acamera 24 and an infrared sensor 403, and a second inspection station211, which further includes a monitor 30.

In the example embodiment illustrated in FIG. 4, the system 401 includesa sorting station 202 which is configured to allow initial sorting of asource of wheels according to a first set of criteria, with wheels notmatching the first set of criteria being placed in a first scrapreceptacle 48 a. A loading station 206 is provided, which is configuredto allow placement of each wheel matching the first set of criteria ontoa first conveyor 203. In some embodiments, the loading station 206 mayinclude a hopper above a vibrating chute, with the hopper configured forfork lift dumping of wheels into the hopper, and with the vibratingchute configured to position the wheels for loading onto the firstconveyor 203.

In the example embodiment illustrated in FIG. 4, the first conveyor 203may be a powered accumulation roller conveyor defining a plurality ofregions, or “zones,” along the length thereof, identified as “zone 4”,“zone 3”, “zone 2” and “zone 1” for positioning and accumulation ofincoming wheels. The first conveyor 203 may be configured to receiveincoming wheels and to accumulate the incoming wheels, with the firstwheel stopping automatically in zone 1 awaiting a signal from thecontrol module to advance the wheel onto the second conveyor 405, withother incoming wheels accumulating behind the wheel in zone 1 back inzones 2 through 4. When the control module advances the first conveyor203 to move the wheel from zone 1 of the first conveyor 203 onto thesecond conveyor 405, each of the other wheels on the first conveyor 203also advances to the next zone.

In the example embodiment illustrated in FIG. 4, the second conveyor 405may be a powered belt conveyor controlled by the control module andconfigured to position each incoming wheel under the camera 24 and todischarge the wheels evenly spaced onto the third conveyor 208. Thecamera 24 may be disposed above the second conveyor 405 and configuredto capture the image of the wheel once it is stopped on the secondconveyor 405. The infrared sensor 403 may be disposed proximate to thesecond conveyor 405 and configured to measure the height and width ofthe wheel once it is stopped on the second conveyor 405.

In one embodiment, a first inspection station 204 a may be disposedalong the first conveyor 203 and the second conveyor 405. The controlmodule of the first inspection station 204 a may be in operativecommunication with the wheel sensor 205 a and the wheel sensor 205 b,and the control module 207 may be in operative control of the firstconveyor 203, the second conveyor 405, the camera 24, the infraredsensor 403, the third conveyor 208, the diverter mechanism 209, and thefifth conveyor 214. The first wheel sensor 205 a may be disposed alongthe first conveyor 203 and configured to detect a wheel moving into zone1 of the first conveyor 203 and to signal the control module 207 to stopthe first conveyor 203 with the wheel in zone 1. If no wheel is presenton the second conveyor 405, the control module 207 may signal the firstconveyor 203 to move the wheel from zone 1 of the first conveyor 203onto the second conveyor 405. The second wheel sensor 205 b may bedisposed along the second conveyor 405 and configured to detect a wheelpositioned on the second conveyor 405 and to signal the control module207 that a wheel is in position on the second conveyor 405. The controlmodule 207 may then signal the camera 24 to capture and communicate tothe control module 207 an image of the wheel located on the secondconveyor 405 and may signal the infrared sensor 403 to take andcommunicate to the control module 207 measurements of the height andwidth of the wheel located on the second conveyor 405. Once the controlmodule 207 has received the image and measurements for the wheel, thecontrol module 207 may signal the second conveyor 405 to advance thewheel onto the third conveyor 208. As will be further discussed hereinbelow, a computer (not shown) may be integrated into or otherwise incommunication with the control module 207 and may include computersoftware which may be configured to identify the wheel imaged by thecamera 24 and to compare the identified wheel to a second set ofcriteria to determine if the wheel is to be kept.

In the example embodiment illustrated in FIG. 4, a third conveyor 208may be a powered roller conveyor controlled by the control module 207and configured to receive a plurality of evenly spaced wheels dischargedby the second conveyor 405. The third conveyor 405 may be configured todirect the received wheels to a diverter mechanism 209, whereupon thediverter mechanism 209 may divert wheels conforming to the second set ofcriteria from the third conveyor 208 onto the fourth conveyor 213. Inseveral embodiments, the diverter mechanism 209 comprises a piston,lever arm, or other such device. However, those of skill in the art willrecognize other suitable devices which may be used to accomplish theoperation performed by the diverter mechanism 209 without departing fromthe spirit and scope of the present general inventive concept. Inseveral embodiments, the third conveyor 208 maintains the spacing of thereceived wheels along a length of the third conveyor 208 in order toassist in timing of the diverter mechanism 209.

In the example embodiment illustrated in FIG. 4, the fourth conveyor 213may be a gravity powered wheel conveyor configured to receive thediverted wheels and to direct the diverted wheels to a second inspectionstation 211. The second inspection station 211 may be disposed along thefourth conveyor 213 and configured to allow examination of the divertedwheels by an operator 28. At the second inspection station 211, theoperator 28 may confirm whether each wheel conforms to the second set ofcriteria. Wheels conforming to the second set of criteria may be placedonto a core skid 46, and wheels not conforming to the second set ofcriteria may be placed in a second scrap receptacle 48 b and discarded.

Those wheels not diverted by the diverter mechanism 209 may be carriedby the third conveyor 208 to a discharge end of the third conveyor 208.In the example embodiment illustrated in FIG. 4, a fifth conveyor 214may be a powered roller conveyor controlled by the control module 207and configured to receive the wheels from the discharge end of the thirdconveyor 208 and to direct the received wheels through a cleaningstation 215 and on to the discharge end of the fifth conveyor 214. Thecleaning station 215 may be configured to manipulate and clean thewheels prior to the wheels being discharged onto a sixth conveyor 216.

In the example embodiment illustrated in FIG. 4, a sixth conveyor 216may be a powered accumulation roller conveyor defining a plurality ofregions, or “zones,” along the length thereof, identified as “zone 5”,“zone 4”, “zone 3”, “zone 2” and “zone 1” for positioning andaccumulation of wheels. The sixth conveyor 216 may be configured toreceive the clean wheels discharged from the fifth conveyor 214, toaccumulate the clean wheels, and to direct them to the wrapper station407, with the first wheel stopping automatically in zone 1 of the sixthconveyor 216, and with other incoming clean wheels accumulating behindthe wheel in zone 1, back in zones 2 through 5 of the sixth conveyor216. When a wheel is removed from zone 1 of the sixth conveyor 216 to beloaded on a pallet, each of the other wheels on the sixth conveyor 216automatically advances to the next zone.

In the example embodiment illustrated in FIG. 4, the wrapper station 407may include a gravity powered seventh conveyor deck attached to ahydraulic scissor lift and configured to hold a pallet while wheels areloaded onto a pallet and wrapped for shipping by a rotating boom stylewrapper disposed above and around a pallet positioned on the seventhconveyor deck of the wrapper station 407. As wheels are removed fromzone 1 of the sixth conveyor 216 and loaded in layers on the palletpositioned on the seventh conveyor deck of the wrapper station 407, thescissor lift of the wrapper station 407 may be configured to lower theseventh conveyor deck of the wrapper station 407 to position the palletfor loading of each layer of wheels and then to raise the seventhconveyor deck of the wrapper station 407 to the level of the eighthconveyor 409 once it is fully loaded with wheels. As the pallet isloaded in layers, the rotating boom style wrapper may be moved aroundthe pallet to wrap the pallet and multiple layers of the wheels on thepallet with overlapping wraps to secure the wheels to the pallet forshipping. Once the pallet is fully loaded and wrapped, the loaded andwrapped pallet may be pushed from the seventh conveyor deck of thewrapper station 407 onto the eighth conveyor 409.

In the example embodiment illustrated in FIG. 4, the eighth conveyor 409may be a powered accumulation roller conveyor defining a plurality ofregions, or “zones,” along the length thereof, identified as “zone 3”,“zone 2” and “zone 1” for positioning and accumulation of loaded andwrapped pallets. The eighth conveyor 409 may be configured to receivewrapped pallets of wheels from the seventh conveyor deck of the wrapperstation 407 and to accumulate the pallets awaiting removal by a forklift, with the first loaded and wrapped pallet stopping automatically inzone 1 of the eighth conveyor 409, and with subsequent loaded andwrapped pallets accumulating behind the pallet in zone 1, back in zones2 and 3 of the eighth conveyor 409. When a loaded and wrapped pallet isremoved from zone 1 of the eighth conveyor 409, each of the otherpallets on the eighth conveyor 409 automatically advances to the nextzone.

In the example embodiment illustrated in FIG. 4, the first conveyor 203,second conveyor 405, the third conveyor 208, and the fifth conveyor 214are each electronically controlled by the control module 207, which isalso in operative communication with the first wheel sensors 205 a andthe second wheel sensor 205 b. Thus, the control module 207 may signaleach conveyor to advance as needed to maintain sufficient pace andspacing of wheels along the second, third and fifth conveyors 405, 208,214. In the illustrated embodiment, the fourth conveyor 213 is agravity-driven conveyor, such as for example a ramp or other suitabledevice, and the first conveyor 203, the sixth conveyor 216 and theeighth conveyor 409 are powered accumulation conveyors with definedzones configured for accumulation and automatic advancement of wheels orpallets from zone to zone. However, those of skill in the art willrecognize other means for controlling the various conveyors 203, 405,208, 213, 214 which may be used without departing from the spirit andscope of the present general inventive concept. For example, in otherembodiments, the third conveyor 213 and the conveyor deck of the wrapperstation 407 may be powered by automated means known to those of skill inthe art.

In the embodiment illustrated in FIG. 4, the control module 207 includesa computer (not shown), integrated into or otherwise in communicationwith the control module 207, with said computer having appropriate imagerecognition software, of the type known to one skilled in the art, suchthat the computer is able to analyze an image provided by the camera 24,identify the closest matches to the imaged wheel from a wheel featuredatabase stored in the computer, and determine whether each potentialmatch for the wheel depicted in the image conforms to, or fails, thesecond set of criteria. Upon a determination that the wheel depicted inthe image conforms to the second set of criteria, a signal is generatedby the control module 207 and communicated to the diverter mechanism 209in cooperation with the movement of the wheel along the third conveyor208 and the arrival of the wheel in front of the diverter mechanism 209.In the embodiment illustrated in FIG. 4, the diverter mechanism 209 isconfigured to be responsive to the signal such that, upon receipt of thesignal, the diverter mechanism 209 is activated to push the wheel fromthe third conveyor 208 onto the fourth conveyor 213. Thus, in thisembodiment, the camera 24, the computer in the control module 207, thethird conveyor 208, and the diverter mechanism 209 work in cooperationwith one another to automatically direct each wheel either to the fourthconveyor 213 for confirmation by the operator 28 or to the discharge endof the third conveyor 208 based on the determination of the computerintegrated into or otherwise in communication with the control module207.

In some embodiments, the first inspection station 204 a is automated tocontrol the movement of the first conveyor 203, the second conveyor 405,the third conveyor 208, and the fifth conveyor 214, so that the wheelsare evenly spaced as they pass in front of the diverter mechanism 209.Referring now to FIG. 4 and FIG. 5, the wheel sensor 205 a initiates asignal to the control module 207 when a wheel is approaching the camera24, and in response to the signal, the control module 207 stops thefirst conveyor 203 with the wheel in zone 1 of the first conveyor 203.After the control module 207 determines that the diverter mechanism 209is no longer in a push cycle, the control module 207 signals acontroller 301 to start a motor 302 and propel the first conveyor 203 tomove the wheel onto the second conveyor 405 to a point where the wheelis position on the second conveyor 405 under the camera 24, receives asignal from the second wheel sensor 205 b that the wheel is in theproper position, signals the camera 24 to capture the image of thewheel, signals the infrared sensor 403 to take measurements of theheight and width of the wheel, and then signals the controller 501 tostart the motor 502 and advance the second conveyor 405 to move thewheel onto the third conveyor 208. When the second conveyor 405 hasmoved the distance required to discharge the wheel onto the thirdconveyor 208, the control module 207 signals a controller 305 to start amotor 306 and advance the third conveyor 208 a set distance. If thethird conveyor 208 discharged a wheel onto the fifth conveyor 214, thecontrol module 207 also signals a controller 309 to start a motor 310and advance the fifth conveyor 214 the same set distance. In someembodiments, the third conveyor 208 and the fifth conveyor 214 are eachadvanced a selected distance, thirty-four (34) inches in an exemplaryembodiment, each time they are advanced so that the wheels remain evenlyspaced on the third conveyor 208 as they move in front of the divertermechanism 209 and remain evenly spaced on the fifth conveyor 214 as theymove into the cleaning station 215. This equal spacing of the wheelsallows the control module 207 to track the location of each wheel andsignal the diverter mechanism 209 to push each wheel matching the set ofcriteria from the third conveyor 208 onto the fourth conveyor 213 as thematching wheel moves in front of the diverter mechanism 209. This equalspacing of the wheels also places the wheels on the fifth conveyor 214in the proper position for pickup and manipulation as each wheel entersthe cleaning station 215. In other embodiments, a wheel sensor may bedisposed at the receiving end of the fifth conveyor 214 to detectwhether a wheel is present and to notify the control module not toadvance the fifth conveyor 214 the set distance if no wheel is present,thus permitting the fifth conveyor 214 to maintain even spacing ofwheels with no gaps where wheels have been diverted onto the fourthconveyor 213. One of skill in the art will understand that theabove-mentioned example dimensions are not meant to be limiting, andthat other values may be substituted for the set distance of thirty-fourinches for advancement of the respective conveyors without departingfrom the scope or spirit of the present general inventive concept.

Referring now to FIG. 6, in some embodiments, the control module 207 isconfigured with a computer (not shown) integrated into or otherwise incommunication with the control module 207 which is capable of performingthe various desired processing and control operations of the controlmodule 207, with one such operation being a routine to populate a wheelfeature database for known wheels based on digital images of knownwheels.

In the embodiments illustrated in FIG. 6, the computer routine topopulate a wheel feature database for known wheels includes receivingimages of a known wheel 650 in the form of digital images received fromthird parties or from images taken by the camera 24, together with wheeldata entered by an operator using a computer terminal, which data mayinclude a unique identifying number, wheel dimensions, makes and modelsof automobiles using the wheel, and similar information. Once the knownwheel information and image has been received by the computer, a loadingroutine to populate the wheel feature database is initiated 652.

Once the routine to populate the wheel feature database is initiated652, the computer follows the steps set forth in the block diagram inFIG. 7. Referring now to FIG. 7, the subroutine loads the wheel imagefor the known wheel 702. The subroutine normalizes and converts thewheel image to uniform grayscale 704, and finds the wheel boundary andthe center of the wheel 706. The subroutine samples a plurality ofpoints on multiple circles around the wheel center 708, and computes theFourier transform magnitudes of sampled points on multiple circles ofthe wheel image to generate features of the wheel 710. The subroutinestores the features of the wheel in the wheel feature database 712, anddetermines whether there are more wheels to process 714. If thesubroutine determines that there are more wheels to process, thesubroutine begins the process for the next known wheel by loading thewheel image for the next wheel 702. Once the subroutine determines thereare no more wheels to process, the subroutine computes the K-nearestneighbor classifier using the features of all known wheels in the wheelfeature database 716, and the subroutine saves the K-nearest neighborclassifier 718 for subsequent matching.

In some embodiments of the present inventive concept, the subroutine 710of FIG. 7 that computes Fourier transform magnitudes of sampled pointson multiple circles of the wheel image to generate features of the knownwheel comprises building a matrix which stores the calculated Fouriertransform magnitude for each sampled point, with the X-axis of thematrix representing the sampled circles and the Y-axis of the matrixrepresenting the sampled points on each circle. In some embodiments ofthe present inventive concept, the subroutine 716 of FIG. 7 computes aK-nearest neighbor classifier using the wheel feature database.

Referring again to FIG. 6, in some embodiments, the control module 207and its computer, integrated into or otherwise in communication with thecontrol module 207, are capable of performing the various desiredprocessing, matching and control operations of the control module 207,with one such operation being a wheel matching routine comprising asystem and method of controlling various components of the wheel sortingsystem 201, 401 as unknown wheels move through the system, for thepurpose of matching images of the unknown wheels with images of knownwheels, identifying the closest matches to the unknown wheel, anddetermining which potential matches for the wheels match a second set ofcriteria.

Referring now to FIG. 6, as shown at 660, the wheel matching routine isinitiated by the control module 207 after it receives a signal from awheel sensor 205, 205 a that a wheel is approaching the camera 24. Asshown at 662, the control module 207 immediately stops conveyor 203before the unknown wheel moves under the camera 24. As shown at 664, thecontrol module 207 then starts conveyor 203 to direct the wheel towardthe camera 24. When the wheel is under the camera 24, the control module207 signals the camera 24 to capture the image of the wheel and signalsthe infrared sensor 403 to take the wheel measurements, and advances thewheel onto the next conveyor 208. The control module 207 then starts andadvances conveyor 208 and conveyor 214 the same set distance, so thatthe wheels are evenly spaced on conveyors 208, 214, with each wheelarriving directly in front of the diverter mechanism for transfer toconveyor 213 if the wheel is selected as matching the second set ofcriteria. As shown at 666, the control module 207 receives the imagefrom the camera 24 and initiates the wheel matching routine illustratedin FIG. 9 and described in more detail below. As shown at 668, the knownwheels that potentially match the unknown wheel are compared to a secondset of criteria, including a buy list and other business criteriapreviously entered into the computer, to determine if the incoming wheelis to be selected. As shown at 670, the computer of the control module207 then determines whether each potential wheel match satisfies thesecond set of criteria. As shown at 674, if a potential wheel matchsatisfies the second set of criteria, the control module 207 triggersthe diverter mechanism to push the wheel off conveyor 208 and ontoconveyor 213 when the selected wheel is directly in front of thediverter mechanism 209. As shown at 676, the wheel image and potentialwheel match information are sent to an operator queue for display on themonitor 30 next to the operator in the second inspection station 211. Asshown at 672, if a potential wheel match does not satisfy the second setof criteria, the matching results for that wheel are stored in thecomputer for later display on a monitor if requested by an operator, theroutine ends, and the diverter mechanism is not activated for thatwheel, thus allowing it to continue to the end of conveyor 208 and ontoconveyor 214 for cleaning in the cleaning station 215 and ontoaccumulation conveyor 216.

Once the wheel matching routine is initiated 666, the computer followsthe steps set forth in the block diagram in FIG. 8. Referring now toFIG. 8, the subroutine loads the wheel image for the unknown wheel 802.The subroutine normalizes and converts the wheel image to uniformgrayscale 804, and finds the wheel boundary and the center of the wheel806. The subroutine samples a plurality of points on multiple circlesaround the wheel center 808, and computes the Fourier transformmagnitudes of sampled points on multiple circles of the wheel image togenerate features of the wheel 810. The subroutine applies the storedK-nearest neighbor classifier to features of the unknown wheel andreturns the K closest matches to the unknown wheel 812, and thesubroutine assigns and reports scores to K closest matches for the wheelfor later display on a monitor. The wheel matching routine ends for thatwheel and control is returned to the main program. In some embodimentsof the present general inventive concept, the computer software routinethat applies the K-nearest neighbor classifier to return the K closestmatches for an unknown wheel is configured to limit the number of knownwheels to be compared with the unknown wheels by selecting only knownwheels which have the same height and width as the height and width ofthe unknown wheel.

In some embodiments of the present inventive concept, the subroutine 810of FIG. 8 that computes Fourier transform magnitudes of sampled pointson multiple circles of the wheel image to generate features of theunknown wheel comprises building a matrix which stores the calculatedFourier transform magnitude for each sampled point, with the X-axis ofthe matrix representing the sampled circles and the Y-axis of the matrixrepresenting the sampled points on each circle. In some embodiments ofthe present inventive concept, the subroutine 812 of FIG. 8 that appliesstored K-nearest neighbor classifier to features of the unknown wheelcomprises comparing the features of an unknown wheel with the featuresof known wheels using the K-nearest neighbor classifier to determine thenearest potential matches of the unknown wheel with known wheels in thewheel feature database. Then, the subroutine at 814 compares the levelof each potential match and reports the score level of each potentialmatch for subsequent display on the monitor 30 in front of the operator.In some embodiments of the present inventive concept, the subroutinethat reports the score level of each potential match includes asubroutine that computes the closeness of the features of the unknownwheel to the features of the wheel that potentially matches the unknownwheel and compares the resulting distance of the match to predeterminedparameters in the form of a range of acceptable distances the unknownwheel may be from the known wheel that has been identified as apotential match to the unknown wheel.

In some embodiments of the present inventive concept, an operator at thesecond inspection station performs the steps set forth in the blockdiagram in FIG. 9. Referring to FIG. 9, at 902, the operator reviews thepotential match information for the wheel shown on the monitor 30 andcompares the potential match information to the operator's visualinspection of the wheel. At 904, the operator confirms that anacceptable potential match is shown on the monitor. If an acceptablepotential match is not shown on the monitor 904, the wheel is scrapped906. If an acceptable potential match is shown on the monitor 904, theoperator confirms, by visual inspection and by reviewing the data on themonitor 30, whether the wheel satisfies the second set of criteria 908.If the operator determines 908 that the wheel does not match the secondset of criteria, the wheel feature database is updated with the newimage of the wheel 910, and the wheel is scrapped 912. If the operatorconfirms 908 that the wheel satisfies the second set of criteria, thewheel feature database is updated with the new image of the wheel 914,the wheel is added to the appropriate buy list as a purchase 916, and abarcode is printed for attachment to the wheel 918. After the barcode isattached to the selected wheel, the wheel will be placed on a core skid46 awaiting transfer to the appropriate area for further processing andhandling. In some embodiments of the present inventive concept, acomputer software routine is included that allows the system to learnover time and to become more accurate over time, with the computersoftware routine configured to receive notification by the operatorwhether a potential match was an actual match and configured to replacea poor image of a known wheel previously stored in the wheel featuredatabase with a better image taken by the camera 24 after the operatorconfirms that a potential match of an unknown wheel is a definite matchto a known wheel.

Referring to FIGS. 10A-12B, in a further exemplary embodiment, thecamera systems described herein, both in terms of the systems describedherein and the methods described herein, include auxiliary lighting forenhancing the quality of the images captured by camera 24. In thisregard, it has been discovered that merely relying upon ambient lightingin order to capture images of the wheels 50 often results in poor imagequality. This can be the result of poor lighting in the surrounding areathat results in underexposed images and/or undesired and inconsistentshadows in the images. It can also, in warehouse settings that may havelarge doors, be the result of inconsistent outdoor sunlight, combinedwith intermittent cloud cover, infiltrating into the environment of thecamera 24. It has been discovered since the filing of the commonly ownedparent application Ser. No. 14/298,212 filed on Jun. 6, 2014, thatproviding auxiliary lighting, and, if desired, additionally protectingthe imaging area of camera 24 from ambient light, results in higherquality images captured by camera 24.

In this regard, in an exemplary embodiment, at least a pair of auxiliarylights 60 are positioned proximate camera 24 to shine light down on thewheels 50. Auxiliary lights 60 provide consistent lighting on the wheels50 so as to increase the quality of the images captured by the camera24. In an exemplary embodiment, and to further isolate the camera 24from inconsistent ambient lighting, the camera 24 and its associatedauxiliary lights 60 can be placed within a light hood defined bycompartment 65. Compartment 65 covers a portion of first conveyor 22 andis provided with openings 70 at each end through which wheels 50 canpass. In an exemplary embodiment, the openings 70 can be provided with ascreen 75 which is adapted to further block ambient light and allowswheels 50 to pass through unencumbered. Further, in an exemplaryembodiment, the wheel sensors 205 can be placed within the compartment65. Compartment 65 can include covered access ports 80 to allow accessto the interior of the compartment 65 from the sides. In an exemplaryembodiment, compartment 65 is constructed of a substantially opaquematerial in order to block ambient light from entering compartment 65.The auxiliary lights 60, especially when used in conjunction with alight hood defined by compartment 65, serve to control the amount oflight on the wheels 50 such that the quality of the images captured bythe camera is enhanced.

While the present invention has been illustrated by description ofseveral embodiments and while the illustrative embodiments have beendescribed in detail, it is not the intention of the applicant torestrict or in any way limit the scope of the appended claims to suchdetail. Additional modifications will readily appear to those skilled inthe art. Some of the embodiments described above have included a controlmodule with a computer integrated into or in communication with thecontrol module. However, those skilled in the art will recognize thatone or more computers, switches, controllers, communications interfacesand other components may either be integrated into the control module ordistributed in various locations outside of the control module, but inoperational communication with the control module, without departingfrom the spirit and scope of the present general inventive concept.Those skilled in the art will understand that additional conveyors anddevices may be added to the wheel processing system without departingfrom the spirit or scope of applicant's general inventive concept. Theinvention in its broader aspects is therefore not limited to thespecific details, representative apparatus and methods, and illustrativeexamples shown and described. Accordingly, departures may be made fromsuch details without departing from the spirit or scope of applicantsgeneral inventive concept.

Having thus described the aforementioned invention, what is claimedis:
 1. A method for processing core wheels comprising: receiving digitalimages of known wheels having unique identifying numbers and other wheelinformation received from third party providers; processing the digitalimages of the known wheels to determine features of said known wheels;storing the digital images and the determined features, along with theidentifying numbers for the known wheels in a wheel feature database;providing a supply of unknown used wheels to a first location; capturingand processing digital images of the unknown used wheels to determinefeatures of the unknown wheels; comparing the images and features of theunknown used wheels to the images and the features of the known wheelsstored in the wheel feature database and determining any matches betweenthe known wheels and the unknown used wheels; sorting the unknown wheelsto separate at least a first portion of the unknown used wheelsconforming to a first set of criteria from the supply of the unknownwheels; and transporting the first portion of the unknown used wheels toa second location.
 2. The method for processing core wheels of claim 1further comprising processing images of the first portion of the unknownused wheel supply and spacing the unknown used wheels in the firstportion of the wheel supply at selected intervals.
 3. The method forprocessing core wheels of claim 2 wherein said selected intervals areequal intervals.
 4. The method for processing core wheels of claim 2further comprising: separating a second portion of the unknown usedwheels conforming to a second set of criteria from the first portion ofthe unknown used wheels; transporting the second portion of the unknownused wheels to a third location; verifying conformity of the secondportion of the unknown used wheels to the second set of criteria; andtransporting the remainder of the first portion of the unknown usedwheels not conforming to the second set of criteria to a fourthlocation.
 5. The method for processing core wheels of claim 4, furthercomprising taking measurements of the first portion of the unknown usedwheels and storing said measurements.
 6. The method for processing corewheels of claim 5 wherein the step of processing images of known wheelsto determine the features of said wheels further comprises loading wheelimages and other information received from third party providers,determining the features of the known wheel; and wherein the step ofstoring the features of said wheels for future reference furthercomprises loading the features of the known wheels into the wheelfeature database stored in a computer, and computing and saving aK-nearest neighbor classifier for subsequent matching to images ofunknown used wheels.
 7. The method for processing core wheels of claim 6wherein the step of processing images of the first portion of theunknown used wheel supply further comprises loading the image of anunknown wheel taken by the camera, determining the features of saidunknown wheel, applying K-nearest neighbor classifier to features ofsaid unknown wheel to find the closest potential matches of said unknownwheel with known wheels stored in the wheel feature database, anddetermining whether said potential matches are within predeterminedparameters.
 8. The method for processing core wheels of claim 7 whereinthe step of applying the K-nearest neighbor classifier to find theclosest potential matches for an unknown wheel further comprisescomparing the features of said unknown wheel with the features of knownwheels stored in a K-nearest neighbor classifier and returning thenearest potential matches for said unknown wheel.
 9. The method forprocessing core wheels of claim 8 wherein the step of applying theK-nearest neighbor classifier for the unknown wheel further compriseslimiting the number of known wheels to be compared to the unknown wheelby selecting only known wheels which have a same height and width as aheight and width of the unknown wheel.
 10. The method for processingcore wheels of claim 9 wherein the step of processing images includescontrolling an amount of light on said unknown used wheels wherebyquality of the processed images is enhanced.
 11. A method for processingcore wheels comprising: receiving digital images of known wheels havingunique identifying numbers and other wheel information received fromthird party providers; processing the digital images of the known wheelsto determine the features of said known wheels; storing the digitalimages and the determined features, along with the identifying numbersfor the known wheels in a wheel feature database; providing a supply ofunknown used wheels to a first location; storing the images, featuresand other wheel information for the known wheels in a wheel featuredatabase for future reference; capturing and processing digital imagesof the unknown used wheels to determine features of the unknown usedwheels; comparing the images and features of the unknown used wheels tothe images and the features of the known wheels stored in the wheelfeature database and determining any matches between the known wheelsand the unknown used wheels; sorting the unknown used wheels to separateat least a first portion of the unknown used wheels conforming to afirst set of criteria from the supply of wheels; and transporting thefirst portion of the unknown used wheels to a second location forrefurbishment whereby said first portion of the unknown used wheels canbe refurbished and further directed for reuse.
 12. The method forprocessing core wheels of claim 11 further comprising processing imagesof the first portion of the unknown wheel supply and spacing the wheelsin the first portion of the unknown wheel supply at selected intervals.13. The method for processing core wheels of claim 12 wherein saidselected intervals are equal intervals.
 14. The method for processingcore wheels of claim 12 further comprising: separating a second portionof the unknown used wheels conforming to a second set of criteria fromthe first portion of the unknown used wheels; transporting the secondportion of the unknown used wheels to a third location; verifyingconformity of the second portion of the wheels to the second set ofcriteria; and transporting the remainder of the first portion of theunknown used wheels not conforming to the second set of criteria to afourth location.
 15. The method for processing core wheels of claim 14,further comprising taking measurements of the first portion of theunknown used wheels and storing said measurements.
 16. The method forprocessing core wheels of claim 15 wherein the step of processing imagesof known wheels to determine the features of said wheels furthercomprises loading wheel images and other information received from thirdparty providers, determining the features of the known wheel; andwherein the step of storing the features of said wheels for futurereference further comprises loading the features of the known wheelsinto the wheel feature database stored in a computer, and computing andsaving a K-nearest neighbor classifier for subsequent matching to imagesof unknown used wheels.
 17. The method for processing core wheels ofclaim 16 wherein the step of processing images of the first portion ofthe unknown wheel supply further comprises loading the image of anunknown wheel taken by the camera, determining the features of saidunknown wheel, applying K-nearest neighbor classifier to features ofsaid unknown wheel to find the closest potential matches of said unknownwheel with known wheels stored in the wheel feature database, anddetermining whether said potential matches are within predeterminedparameters.
 18. The method for processing core wheels of claim 17wherein the step of applying the K-nearest neighbor classifier to findthe closest potential matches for an unknown wheel further comprisescomparing the features of said unknown wheel with the features of knownwheels stored in a K-nearest neighbor classifier and returning thenearest potential matches for said unknown wheel.
 19. The method forprocessing core wheels of claim 18 wherein the step of applying theK-nearest neighbor classifier for the unknown wheel further compriseslimiting the number of known wheels to be compared to the unknown wheelby selecting only known wheels which have a same height and width as aheight and width of the unknown wheel.
 20. The method for processingcore wheels of claim 19 wherein the step of processing images includescontrolling an amount of light on said unknown used wheels wherebyquality of the processed images is enhanced.